CAREER: The Production of High Value, Defect-free Metal Castings through Model-based Design and Additive Manufacturing of Sand Molds

职业：通过基于模型的设计和砂型增材制造生产高价值、无缺陷的金属铸件

基本信息

批准号：
1944120
负责人：
Guhaprasanna Manogharan
金额：
$ 50.42万
依托单位：
Pennsylvania State Univ University Park
依托单位国家：
美国
项目类别：
Standard Grant
财政年份：
2020
资助国家：
美国
起止时间：
2020-08-01 至 2025-07-31
项目状态：
未结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=1944120&HistoricalAwards=false
关键词：
CAREER Production Value Defect free

项目摘要

This Faculty Early Career Development (CAREER) grant focuses on the study of metal casting using model-based design and three-dimensional printed sand molds. Metal casting involves pouring of molten metal in a mold made of sand. It is one of the oldest and most widely used manufacturing processes in the production of parts and components for many industrial applications. However, traditional metal casting suffers from high scrap rates because it is still regarded as a process that is empirically designed and with high uncertainty even in controlled processing environments. Due to the nature of the two-dimensional geometry of pathways for the molten metal, turbulent flow traps air in the melt and causes defects in the solidified castings. This results in poor mechanical properties along with additional costs and energy to repair or scrap the castings. This project conducts fundamental research to enable new numerical models and computational capabilities to study the complex relationships between the three-dimensional geometry of the sand mold and reduction in defects in the sand castings. This research is complemented by an integrated educational and outreach program based on new course development to be strategically deployed across the U.S through a network of foundry educators. In addition, a manufacturing education center at the home institution is leveraged for underrepresented minority and K-12 student outreach. The goal of this research is to understand the effects of 3D freeform gating and riser geometry in sand casting on reducing defects and improving the mechanical properties of metal castings. Turbulent filling of molten metal results in the formation of oxide bifilms, air entrapment and porosity in castings, which adversely impact their mechanical performance. The research objectives of the project are: (1) Understand the effects of 3D free-form gating and riser design on air entrapment and formation of oxide bifilms during mold filling, and (2) Characterize the relationship between 3D freeform gating and riser system and solidification behavior and their impact on mechanical strength. This project leverages an additive manufacturing process, namely binder-jetting of foundry sand or 3D sand-printing for the fabrication of sand molds for metal casting. This research establishes a fundamental understanding of 3D gating and riser design geometries in sand molds for defect-free metal castings. Melt flow velocity, fluid dynamics, solidification rate, and microscopic properties such as dendrite arm spacing, inclusions and porosity are investigated. Design principles for 3D gating and riser geometries that can be achieved by 3D sand-printing of molds are developed and validated. This project enables the PI to advance the knowledge of metal casting science, computational fluid dynamics modeling and in-process monitoring of the casting process and establishes the foundation for a long-term career in advanced manufacturing.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

该学院早期职业发展 (CAREER) 资助的重点是使用基于模型的设计和三维打印砂模来研究金属铸造。金属铸造涉及将熔融金属浇注到由沙子制成的模具中。它是许多工业应用零部件生产中最古老、使用最广泛的制造工艺之一。然而，传统金属铸造的废品率很高，因为它仍然被认为是一种凭经验设计的工艺，即使在受控的加工环境中也具有很高的不确定性。由于熔融金属通道的二维几何形状的性质，湍流会在熔体中捕获空气并导致凝固铸件中的缺陷。这会导致机械性能较差，并增加修复或报废铸件的成本和能源。该项目进行基础研究，以启用新的数值模型和计算能力来研究砂型的三维几何形状与减少砂铸件缺陷之间的复杂关系。这项研究得到了基于新课程开发的综合教育和推广计划的补充，该计划将通过铸造教育工作者网络在美国各地战略部署。此外，母校的制造业教育中心还用于宣传少数族裔和 K-12 学生。本研究的目的是了解砂型铸造中 3D 自由形状浇口和冒口几何形状对减少缺陷和提高金属铸件机械性能的影响。熔融金属的湍流填充会导致铸件中形成氧化物双膜、滞留空气和孔隙，从而对其机械性能产生不利影响。该项目的研究目标是：(1) 了解 3D 自由形状浇注和冒口设计对模具填充过程中空气滞留和氧化物双膜形成的影响，以及 (2) 表征 3D 自由形状浇注和冒口系统之间的关系以及凝固行为及其对机械强度的影响。该项目利用增材制造工艺，即铸造砂的粘合剂喷射或 3D 砂打印来制造金属铸造的砂模。这项研究建立了对无缺陷金属铸件砂模中 3D 浇口和冒口设计几何形状的基本了解。研究了熔体流动速度、流体动力学、凝固速率以及枝晶臂间距、夹杂物和孔隙率等微观特性。开发并验证了可通过模具 3D 砂打印实现的 3D 浇口和冒口几何形状的设计原则。该项目使 PI 能够提高金属铸造科学、计算流体动力学建模和铸造过程过程中监控的知识，并为先进制造领域的长期职业生涯奠定基础。该奖项反映了 NSF 的法定使命，并已被通过使用基金会的智力优点和更广泛的影响审查标准进行评估，认为值得支持。